Enhanced solar-driven evaporation and mineral extraction from hypersaline produced water using low-cost microporous photothermal foam.

The beneficial reuse of produced water (PW) holds significant promise to alleviate water scarcity. However, it still suffers major limitations associated with the high cost of treatment due to energy consumption, economics of scale, and the complex physiochemical constituents. PW is a hypersaline (TDS ∼ 250,000 mg/l) oilfield water with bio-species, organic matter, anions, divalent cations, and radioactive elements. A sustainable treatment option is solar-driven floating photothermal evaporation (PTE), a desalination technology implemented for seawater characterized by simpler chemical compositions and low salinity. In this work, the photothermal evaporator for PW was fabricated using low-cost commercially available charcoal polyurethane foam. The engineered macrochannels and structural alterations created unique pathways for salt extraction and evaporation; and ensured hydrodynamic balance between the rates of capillary flow and evaporation. This novel design mitigated flooding or dry out on the evaporating surface and kept the system running steadily while simultaneously harvesting freshwater and valuable salts. The key findings from this work are (a) the development of a novel temperature ratio-based method to determine optimum PTE thickness that results in maximum evaporation and thermal localization, (b) the development of the empirical correlation between the rate of thermal localization, evaporation rate, and PTE thickness. It combines the interplay of convection, evaporative flux, conduction, heat capacitance, and thickness on the thermal response of PTE foam to incident solar flux, and (c) experimental evidence revealing efflorescence and subflorescence salt on the evaporating surface and pore, and (d) enhanced evaporation rate of 118 % or 71.6 kg/day-m of clean water from chemically complex hypersaline produced water. These findings are significant for the engineering design and estimation of the performance of a PTE in a solar-driven evaporation system.